Chain-Sprocket Drives

A chain drive consists of an endless chain wrapped around two sprockets as shown. The chain consists
of a number of links connected by pin joints, while the sprockets are toothed wheels with a special
profile for teeth. The chain drive is intermediate between belt and gear drives. It has some features of
belt drives and some of gear drives. The advantages and disadvantages of chain drive compared with
belt and gear drives are as follows:
(i) Chain drives can be used for long as well as short centre distances. They are particularly suitable for
medium centre distance, where gear drives will require additional idler gears.

(ii) As shown, a number of shafts can be driven in the same or opposite direction by means of the
chain from a single driving sprocket. The requirements for this type of operation are parallel shafts
with sprockets in the same plane.
(iii) Chain drives are used for shafts, which are parallel. Some types of gears, like bevel and worm
gears, are used for non-parallel shafts.
(iv) Chain drives are more compact than belt or gear drives.
(v) The efficiency of chain drives is high, at times as high as 98%.
(vi) A chain drive does not slip and to that extent, it is a positive drive compared to the belt drive.
However, it is unsuitable where precise motion is required due to polygonal effect and wear in the
joints.
(vii) Compared with belt drives, chain drives require precise alignment of shafts. However, the centre
distance is not as critical as in the case of gear drives.
(viii)Compared with belt drives, chain drives require proper maintenance, particularly lubrication and
slack adjustment. However, chains can be easily replaced.
(ix) Although they generate noise, they present no fire hazards and are unaffected by high
temperatures or atmospheric conditions.

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Chain drives are popular in the transportation industry, such as bicycles, motorcycles and automobile
vehicles. They are used in metal and wood working machinery for the transmission of power. They are
used in textile, building construction and materials handling machinery. Chain drives are used for
velocity ratios less than 10: 1 and chain velocities up to 25 m/s. In general, they are recommended to
transmit power up to 100 kW.

Roller Chain
The construction of a roller chain is shown. It consists of alternate links made of inner and outer link-
plates. There are five parts of roller chain-namely, pin, bushing, roller and inner and outer link-plates.
The pin is press fitted to two outer link-plates, while the bush is press fitted to inner link-plates. The bush
and the pin form a swivel joint and the outer link is free to swivel with respect to the inner link.
The rollers are freely fitted on bushes and, during engagement, turn with the teeth of the sprocket
wheels. This results in rolling friction instead of sliding friction between the roller and sprocket teeth and
reduces wear. The pins, bushes and rollers are made of alloy steels. The pitch (P) of the chain is the
linear distance between the axes of adjacent rollers. Roller chains are standardized and manufactured
on the basis of the pitch. These chains are available in single-row or multi-row constructions such as
simple, duplex or triplex strands as shown in the figure. The dimensions and breaking load of standard
chains (Code: IS: 2403-1975: Specifications for transmission steel roller chains and chain wheels) are
given in table.

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Geometric Relationship
The engagement of chain on sprocket wheel is shown in the figure. D is the pitch circle diameter of the
sprocket and α is called the pitch angle.
360
α= , where z is the number of teeth on the sprocket wheel.
z
From figure,
⎛ α ⎞ (p / 2) p p
sin ⎜ ⎟ = ⇒D= ∴D =
⎝ 2 ⎠ (D / 2) ⎛α⎞
sin ⎜ ⎟
⎛ 180 ⎞
sin ⎜ ⎟
⎝2⎠ ⎝ z ⎠
Velocity Ratio i of the chain drive is given by
n z
i = 1 = 2 , where n , n are rotational speeds of driving and driven shafts respectively
n z 1 2
2 1
(rpm) and z , z are numbers of teeth on driving and driven sprockets respectively.
1 2
The average velocity of the chain is given by
πDn zpn
v=
3
( m/ s ) = ( m/ s )
60 × 10 60 × 103
The length of the chain is expressed as
L = L × p , where L is the length of the chain in mm L is the number of links in the chain.
n n
Also number of links in the chain is determined by the following approximate relationship:
2
⎛ a ⎞ ⎛ z1 + z 2 ⎞ ⎛ z2 − z1 ⎞ ⎛ p ⎞
L = 2⎜ ⎟ + ⎜ ⎟+⎜ ⎟ ⋅⎜ ⎟
n ⎝ p ⎠ ⎝⎜ 2 ⎟⎠ ⎜⎝ 2π ⎟⎠ ⎝ a ⎠

where,
a =centre distance between axes of driving and driven sprockets (mm)
z = Number of teeth on the smaller sprocket
1
z = Number of teeth on the larger sprocket
2
The above formula is derived by analogy with the length of the belt. The first two terms represent the

(
number of links when z = z
1 2 ) and the sides of the chain are parallel. The third term takes into
consideration the inclination of the sides. It is obvious that the chain should contain a whole number of
links. Therefore the number of links ( L ) is rounded to the next digit. It is always preferred
n
to have 'even' number of links, since the chain consists of alternate pairs of inner and outer
link-plates. When the chain has odd number of links, an additional link, called 'offset' link is
provided. The offset link is, however, weaker than the main links. After selecting the exact

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number of links, the centre-to-centre distance between the axes of the two sprockets is
calculated by the following formula:
⎡ 2 2⎤
⎛ p ⎞ ⎢ ⎧⎪ ⎛ z + z ⎞ ⎫⎪ ⎧⎪ ⎛ z + z ⎞ ⎫⎪ ⎛ z −z ⎞ ⎥
a = ⎜ ⎟ ⎢ ⎨L − ⎜ 1 2 ⎟ ⎬ + ⎨Ln − ⎜⎜
1 2 ⎟ − 8⋅⎜ 2 1 ⎟
⎝ 4 ⎠ ⎢ ⎩⎪ n ⎜⎝ 2 ⎟⎠ ⎭⎪ ⎟⎬ ⎜ 2π ⎟ ⎥
⎩⎪ ⎝ 2 ⎠ ⎭⎪ ⎝ ⎠ ⎥
⎣ ⎦
The above equation can be easily derived from the equation for the number of links. The
centre distance calculated by the formula does not provide any sag. In practice, a small
amount of sag is essential for the links to take the best position on the sprocket wheel. The
centre distance is, therefore, reduced by a margin of (0.002 to 0.004) times “a” to account
for the sag.

Polygonal Effect
The chain passes around the sprocket as a series of chordal links. This action is similar to that of a non-
slipping belt wrapped around a rotating polygon. The chordal action is illustrated in the figure, where the
sprocket has only four teeth. It is assumed that the sprocket is rotating at a constant speed of n r.p.m. In
the figure, the chain link AB is at a distance of (D/2) from the centre of the sprocket wheel and its linear
velocity is given by
πDn
v
max
= (m / s)
60 × 103

⎛α⎞
As the sprocket rotates through an angle ⎜ ⎟ the position of the chain link AB is shown in the figure.
⎝2⎠
D ⎛α⎞
In this case the link is at a distance of × cos ⎜ ⎟ from the centre of the sprocket and its linear
2 ⎝2⎠
velocity is given by
⎛α⎞
π D n cos ⎜ ⎟
⎝ 2 ⎠ m/ s
v
min
= ( )
60 × 103

It is evident that the linear speed of the chain is not uniform but varies from v to v during every
max min
cycle of tooth engagement. This results in a pulsating and jerky motion. The variation in velocity is given
by

( vmax − vmin ) ∝ ⎨⎩⎧1− cos ⎜⎝⎛ α2 ⎟⎠⎞⎬⎭⎫ (m/ s ) or

( vmax − vmin ) ∝ ⎨⎩⎧1− cos ⎜⎝⎛ 180z ⎟⎠⎞⎬⎭⎫ (m/ s )

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As the number of teeth increases to ∝ the variation will be zero. In order to reduce the
variation in chain speed, the number of teeth on the sprocket should be increased. It has
been observed that for a sprocket of 11 teeth, the speed variation is 4%, for 17 teeth the
variation is 1.6% and for 24 teeth the variation is less than 1%.
For smooth operation at moderate and high speeds, it is considered a good practice to use a
driving sprocket with at least 17 teeth. From durability and noise considerations, the
minimum number of teeth on the driving sprocket is 19 or 21. It is better to use an odd
number of teeth, such as 17, 19 or 21, for the driving sprocket. The odd number of teeth of
the sprocket, in combination with an even number of chain links, facilitates more uniform
wear. In this case, a particular tooth of the sprocket wheel does not come in contact with a
particular link of the chain for every cycle of rotation. The chain is elongated due to wear in
the joints. Such a chain has a tendency to shift outward upon the teeth of the sprocket.
When the sprocket has a large number of teeth, and consequently small pitch, even a small
elongation of the chain results in a larger shift to the chain along tooth profiles. The outward
shift of the chain limits the maximum number of teeth on the sprocket. For roller chains, the
recommended maximum number of teeth for the sprocket wheel is 100 to 120.

Power Rating of Roller Chain

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P = Allowable tension in the chain (N)
1
v = Average velocity of chain (m/s)
However, it is not easy to determine the allowable tension in the chain. It depends upon a
number of factors, such as the type of chain, pitch of the chain link, number of teeth on the
smaller sprocket, chain velocity, the type of power source and driven machinery and the
system of lubrication . The power rating of standard chains is obtained on the basis of failure
criteria. There are four basic modes of chain failure - wear, fatigue, impact and galling .
The wear of the chain is caused by the articulation of pins in the bushings. The wear results
in the elongation of the chain, in other words, the chain pitch is increased. This makes the
chain 'to ride out' on the sprocket teeth resulting in a faulty engagement. When the
elongation is excessive, it becomes necessary to replace the chain. The permissible
elongation for the chain is 1.5 to 2.5%. When the chain is properly lubricated, a layer of oil
film between the contacting surfaces of the pin and the bushing reduces wear.
As the chain passes around the sprocket wheel, it is subjected to a tensile force, which
varies from a maximum on the tight side to a minimum on the loose side. The chain link is,
therefore, subjected to one complete cycle of fluctuating stresses during every revolution of
the sprocket wheel. This results in the fatigue failure of side link-plates. For infinite life, the
tensile stresses should be lower than endurance strength of material.
The engagement of rollers with the teeth of the sprocket results in impact. Excessive impact
may lead to the breakage of roller or bushing. Increasing the number of teeth on the
sprocket or reducing chain tension and speed reduces the magnitude of the impact force.
Galling is a stick-slip phenomenon between the pin and the bushing. When the chain tension
is high, welds are formed at the high spots of the contacting area. Such microscopic welds
are immediately broken due to relative motion of contacting surfaces and leads to excessive
wear, even in the presence of the lubricant.
The manufacturer's catalogues give extensive details, like charts and tables, for the power
ratings of chains. They are based on the above criteria of chain failure. Since the chain
manufacturing is a specialized industry, like ball and roller bearings, it is necessary for the
designer to select a proper chain from these catalogues.
The following table gives values of power rating for simple (single-strand) roller chains.
These values are based on the assumption that there are 17 teeth on the driving sprocket
wheel .
For a given application, the kW rating of the chain can be determined from the following
relationship:
( kW to be transmitted ) × K s
kW rating of chain =
K ×K
1 2

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where,
K = Service factor
s
K = Multiple strand factor
1
K = Tooth correction factor
2
The service factor takes into consideration the effect of shocks and vibrations on the power
to be transmitted. The power rating in table is based on the 17 teeth on the driving wheel. In
a given application, the number of teeth on the driving wheel can be less than or more than
17. The tooth correction factor K accounts for this variation. Similarly, the values of the
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power rating given in table are based on the assumption that the chain has a single strand.
There are duplex and triplex chains too. This variation in the number of strands is taken into
account by the multiple strand factor K . The values of factors K , K and K are given in
1 1 2 s
following tables.
For a satisfactory performance of roller chains, the centre distance between the sprockets
should provide at least a 120° wrap angle on the smaller sprocket. In practice, the desirable
centre distance is between 30 to 50 chain pitches.
Therefore, 30p < a < 50p
The expected service life of these chains is 15,000 hr. The velocity ratio should be kept
below 6:1 to get a satisfactory- performance. Chains are lubricated by mineral oils like SAE
30, SAE 40 or SAE 50 . Oil can be manually applied with a brush or a spout can once in
every 8 hours of operation. Drip lubrication, consisting of oil drops directed between link-
plates, or bath lubrication, where the lower strand of chain runs through an oil-sump, are
used for high speed applications.

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Sprocket Wheels
There are different constructions for sprocket wheels as shown in the figure. Small
sprockets up to 100 mm in diameter are usually made of a disk or a solid disk with a hub on
one side (Fig. a and b). They are machined from low carbon steel bars. Large sprockets with
more than 100 mm diameter are either welded to steel hubs or bolted to cast iron hubs (Fig.
c and d). In general, sprockets are made of low carbon or medium carbon steels and, on
rare occasions, stainless steel is also used for sprockets. When the chain velocity is less
than 180 m/min, the teeth of the sprocket wheel are heat-treated to obtain a hardness of 180
B.H.N. For high-speed applications, the recommended hardness is 300 to 500 B.H.N. The
teeth are hardened either by carburising in case of low carbon steel or by quenching and
tempering in case of high carbon steel.

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There are standard profiles for the teeth of a sprocket wheel, as illustrated in the figures.
The principal dimensions of the tooth profile are given in the table.

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Silent Chain
The silent or inverted-tooth chain as shown in the figure, consists of a series of links formed
from laminated steel plates. Each plate has two teeth with a space between them to
accommodate the mating teeth of the sprocket. The sprocket teeth have a trapezoidal
profile. Depending upon the type of joint between links, the silent chains are divided into two
groups-Reynolds chain and Morse chain. In Reynolds chain, the links are connected by pins
resulting in sliding friction. Rocker joints are used in Morse chain. Compared with roller

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chains, the silent chains can be used for high-speed applications. They operate more
smoothly and almost noiselessly. Their reliability is more due to laminated construction.
They are, however, more heavier, more difficult to manufacture and more expensive than
roller chains. Their applications are limited due to these reasons.

Problems
Example 14.1. It is required to design a chain drive to connect a 10 kW, 1440 r.p.m. electric motor to a
centrifugal pump running at 720 r.p.m. The service conditions involve moderate shocks.
(i) Select a proper roller chain and give a list of its dimensions.
(ii) Determine the pitch circle diameters of driving and driven sprockets.
(iii) Determine the number of chain links.
(iv) Specify the correct centre distance between the axes of sprockets.
Solution: In order to reduce the polygonal effect, the number of teeth on the driving sprocket is selected
as 17. It is further assumed that the chain is a simple roller chain with only one strand. The service
factor from table is 1.3.
K = Multiple strand factor =1.0
1
K = Tooth correction factor = 1.0
2
( kW to be transmitted ) × K s
kW rating of chain = =13 kW
K ×K
1 2
Referring to the table, the power rating of the chain 12 B at 1400 r.p.m. is 18.15 kW.
Therefore the chain number 12 B is selected. The dimensions of this chain are as follows:
p = 19.05 mm d = 12.07 mm b = 11.68 mm
1 1

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Find out driver and driven sprocket diameters.
Find out approximate centre distance considering a = 40 p
Put the value in the equation of no. of links and find out no. of links (make it even no.)
Then put the value of no. of links in the centre distance equation to find out correct centre
distance. And give an allowance for sag.

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